SB-110, SB-200TG, SB-210 and SB-310 Single Temp 52768-2-IM
SB-110, SB-200TG, SB-210 and SB-310 Single Temp 52768-2-IM
SB-110, SB-200TG, SB-210 and SB-310 Single Temp 52768-2-IM
6, 02/13)
Single Temperature Systems
SB-110, SB-200TG, SB-210 and SB-310
Trailer Edition
Installation Manual
Providing equipment and services to manage controlled-temperature environments for
food and other temperature-sensitive products, our Climate Control Technologies sector
encompasses both transport and stationary refrigeration solutions. Our product brands include
Thermo King®, a world leader in transport temperature control systems, and Hussmann®, a
manufacturer of refrigeration and food merchandising equipment.
www.thermoking.com www.hussmann.com www.ingersollrand.com
©2004 Ingersoll-Rand Company
Printed in U.S.A. on Recycled Paper
Installation Manual
Trailer Edition
SB-110, SB-200TG, SB-210 and SB-310
Single Temperature Systems
TK 52768-2-IM (Rev. 6, 02/13)
2
Trailer Edition Installation Manual for
SB-110, SB-200TG, SB-210 and SB-310 Systems
3
Introduction
Installation Manual-A was written to assist with the installation of the Thermo King SB-110, SB-200TG, SB-210 and SB-310 Single Temperature
refrigeration systems onto trailers specifically designed and built for refrigerated applications.
Due to its complexity, you should not attempt this installation unless you:
• Are an experienced mechanic
• Can safely lift 34 kilos (75 lbs.)
• Are certified or trained in the repair and maintenance of diesel powered
refrigeration systems
• Have a basic understanding of electricity and electrical wiring
• Have the necessary tools and equipment to complete the installation.
This manual is published for informational purposes only. Thermo King makes no representations warranties express or implied, with respect to
the information recommendations and descriptions contained herein. Information provided should not be regarded as all-inclusive or covering
all contingencies. If further information is required, Thermo King Corporation Service Department should be consulted.
Thermo King’s warranty shall not apply to any equipment which has been “so installed, maintained, repaired or altered as, in the
manufacturer’s judgment, to affect its integrity.”
Manufacturer shall have no liability to any person or entity for any personal injury, property damage or any other direct, indirect,
special, or consequential damages whatsoever, arising out of the use of this manual or any information, recommendations or
descriptions contained herein.
4
Table of Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 Installing the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 Installing the Drain Hoses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Required Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 Installing the Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Installation Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Installing the Fuel Lines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Trailer Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Installing the Status Light Kit (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Evaporator Opening Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Installing the Rear Remote Controller (Option) . . . . . . . . . . . . . . . . . . . . . . 44
Mounting Bolt Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 Installing the Door Switch (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
Unit Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 CargoWatch Sensor Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Bulkhead Dimensions (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Connecting the CargoWatch Sensors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Battery Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Connecting the DAS Sensors - SB-200TG ONLY . . . . . . . . . . . . . . . . . . . . . 56
Status Light Dimensions (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Installing the Bulkhead Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Rear Remote Controller Dimensions (Option) . . . . . . . . . . . . . . . . . . . . . . . 26 Installing the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Door Switch Dimensions (Option) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 Installing the Bottom Pan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Lifting Bar Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 SYSTEM CHECK LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Unpacking the Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
5
Safety Precautions
The symbol appears next to a point that is particularly important:
DANGER: Never operate the unit with the discharge valve WARNING: Keep your hands away from fans and belts
closed because it could cause the compressor to explode, when the unit is running. This should also be considered
causing death or serious injury. when opening and closing the compressor service valves.
7
Required Tools
1. Safety Glasses
2. Drill
3. Drill Bits
4. Tape Measure
5. Mechanics Tools
6. Lifting Bar
7. Work Platform (Recommended)
8. Torque Wrench
9. Forged Eyebolts
10. Deutsch Wedge Remover (P/N 204-799)
11. Deutsch Pin Remover (P/N 204-737)
12. Deutsch Terminal Crimper (P/N 204-1038)
NOTE: Equipment such as scales, gauges, refrigerant leak detectors,
and torque wrenches should be in good working condition and
routinely calibrated to assure accurate readings.
8
Required Tools
9
Installation Components
1. Locking Nuts
2. Washers
3. Self Tapping Screws
4. Clamps
5. Cable Ties
6. Fuel Line Hose
1/4 in.
3/8 in.
7. Fuel Line Fittings
1/4 in.
3/8 in.
8. Fuel Line Connector
9. Drain Hose Check Valve
10. Bulkhead (option)
11. Deutsch 6-Pin Connector, Wedge and Terminal Pins
12. Crimp/Solder Butt Connectors and Heat Shrink Tubing
10
Installation Components
11
Trailer Requirements
DANGER: The front trailer must be structurally strong enough to support the weight of the refrigeration unit!
Approximate Weight
SB-110, SB-200TG, SB-210 and SB-310 = 741 kg (1635 lbs.)
CAUTION: The minimum distance from the king pin to the front of the trailer must be at least 1025 mm (40.354 in.) or severe damage to the
equipment will result. VERIFY THIS DIMENSION BEFORE INSTALLING UNIT!
CAUTION: The minimum clearance required for the swing radius must be 1664.2 mm (65.520 in.) or severe damage to the equipment will
result. VERIFY THIS DIMENSION BEFORE INSTALLING UNIT!
12
Trailer Requirements
13
Evaporator Opening Dimensions
Evaporator Opening
DANGER: The front trailer wall must be structurally strong
enough to support the weight of the refrigeration unit!
The location of the unit mounting bolts and evaporator opening in the front
wall is critical.
VERIFY ALL DIMENSIONS BEFORE INSTALLING UNIT!
NOTE: It may be necessary to relocate the front corner clearance
lights to the corner radius of the trailer to prevent damage.
1. The evaporator opening must be square. The diagonal measurements
must be ±3.0 mm (0.12 in.)
2. The gasket surface around the opening must be at least 76.2 mm
(3.00 in.) wide, be flat ±3.2 mm (0.05 in.) and free of rivets, seams or
bolt heads.
14
Evaporator Opening Dimensions
15
Mounting Bolt Dimensions
16
Mounting Bolt Dimensions
17
Unit Dimensions
I. Front View
II. Side View
III. Top View
18
Unit Dimensions
19
Bulkhead Dimensions (Option)
Bulkhead Function
A bulkhead is used to keep the return airflow from being restricted if the
load shifts. The bulkhead also prevents the load from shifting into the
return airflow passageway on the front wall of the trailer.
20
Bulkhead Dimensions (Option)
21
Battery Dimensions
Refer to Service Bulletin T&T 446 for more information regarding Battery Selection and Maintenance.
Trailer units are designed for one 12 volt, Group 31 battery supplied by the
CAUTION: Do not connect other manufacturer’s equipment or
installer.
accessories to the Thermo King unit! This could result in
severe damage to equipment and void the warranty! The battery must be suitable for deep cycling, heavy duty and rated with a
minimum of 95 amp/hr.
IMPORTANT: The specified battery, electrical wiring and electronic NOTE: See following table for Thermo King approved batteries.
controls were designed to operate and maintain only the Thermo Refer to Service Bulletin T&T 446 for more information regarding
King refrigeration system and factory authorized Thermo King Battery Selection and Maintenance.
options.
750 CCA Wet Cell 925 CCA Wet Cell 1150 CCA Dry Cell (AGM)
Thermo King ReliaMax 750S Thermo King ReliaMax 925N Thermo King EON
P/N 203-731 Threaded Stud P/N 203-733 Threaded Stud P/N 203-550 Threaded Stud
P/N 203-730 SAE Post P/N 203-732 SAE Post P/N 203-551 SAE Post
• Wet Cell Technology • Wet Cell Technology • Dry Cell (AGM) Technology
• Better suited for warmer climates • Better suited for colder climates • Better suited for all applications
• Less cranking power at low • High cranking power at low • High cranking power at lower
ambient temperatures ambient temperatures ambient temperatures
• 18-24 month expected life *see • 18-24 month expected life *see • Suited for extreme temperatures
note below note below • Best for high cycling applications
• Choose for southern climates • Choose for northern climates (Cycle-Sentry use)
• 5-7 year expected life
* NOTE: Wet cell battery life and maintenance requirements are determined by the operating environment and the
charge/discharge rate (cycles) while the battery is in service. Higher ambient temperatures and frequent discharges
will shorten a wet cell battery’s overall life expectancy and increase maintenance requirements.
22
Battery Dimensions
23
Status Light Dimensions (Option)
I. Front View
II. Side View
24
Status Light Dimensions (Option)
25
Rear Remote Controller Dimensions (Option)
I. Front View
II. End View
III. Side View
26
Rear Remote Controller Dimensions (Option)
27
Door Switch Dimensions (Option)
I. Front View
II. Side View
28
Door Switch Dimensions (Option)
I
II II
29
Lifting Bar Dimensions
I. Recommended material: 76.2 mm (3.00 in.) x 12.7 mm (0.50 in.) mild
WARNING: Thermo King requires a 3 point lifting bar to safely
steel.
lift and install units. A lifting bar can be made from the
drawings provided. II. Use forged chain links and hooks, clevis and pins with strength equal to
total lift capacity of hoist mechanism and meet all safety standards.
WARNING: All hardware used to assemble the lifting bar must
be DIN 931 class 10.9 (SAE grade 8). The use of hardware III. Bolt together for maximum strength and safety.
other than specified may cause personal injury, severe
damage to the evaporator and void the warranty.
1. Forged Clevis and Pins
WARNING: The lifting bar and lifting device combined must be
able to support minimum weight of 1360.8 kilos (1 1/2 tons). 2. Forged Connecting Links
3. Forged Locking Hooks
30
Lifting Bar Dimensions
31
Unpacking the Unit
DANGER: Do not use a forklift to install the unit! This could Unpacking the Unit
result in severe damage to the equipment, void the warranty • Carefully remove plastic stretch wrap from unit.
or cause personal injury or death!
• Carefully remove the top cardboard cover.
WARNING: Thermo King requires a 3 point lifting bar to safely • Carefully remove the outer cardboard wrap.
lift and install units. A lifting bar can be made from the drawings
• Remove installation kit boxes, bottom panel, and any other loose
provided (see Lifting Bar Dimensions).
components from rear of unit.
Units are shipped attached to disposable wooden pallet and wrapped with • Attach forged eyebolts and 3 point lifting bar to unit.
protective cardboard and plastic stretch wrap.
• Remove hardware holding unit to wooden pallet.
NOTE: To avoid unnecessary damage to your unit, place the crated
unit near the trailer prior to its removal. • Unit is now ready for installation.
IMPORTANT: DO NOT use a sharp knife to remove the stretch wrap or
cardboard wrap as damage to the exterior of the unit will result!
32
Unpacking the Unit
33
Installing the Unit
WARNING: Do not use a forklift to install the unit! This could Unit Installation
result in severe damage to equipment, void the warranty or 9. Install two 5/8-11 forged lifting eyebolts into threaded holes located on
cause personal injury or death! the top of the unit (Detail I).
WARNING: Use only locking hooks to safely lift the unit! 10. Use the lifting bar to lift unit up to the trailer opening.
Failure to use locking hooks could result in severe damage to NOTE: All nuts that hold the unit to the trailer should be elastic stop
the equipment, void the warranty or cause personal injury or nuts (Nylock Type) provided in the installation kit.
death! (Detail I).
11. Attach washer and elastic stop nuts provided in the installation kit.
WARNING: Thermo King requires a 3 point lifting bar to safely Torque to 82 N•m (60 ft. lbs.).
lift and install units. A lifting bar can be made from the
drawings provided (see Lifting Bar Dimensions).
34
Installing the Unit
35
Installing the Drain Hoses
1. Drain Hoses should run straight down the trailer wall from the unit with
no kinks or bends.
2. Secure with screws and clamps provided in installation kit.
3. Cut off excess hose and attach drain hose check valves provided in
installation kit.
36
Installing the Drain Hoses
37
Installing the Fuel Tank
Installation Recommendations
DANGER: An improperly installed fuel tank could lead to
serious injury or death! Consult your trailer manufacturer for 1. Fuel Tank Channel must be used with every tank installation.
specific details on proper fuel tank installation and
NOTE: This drawing shows a typical installation with 304.8 mm
recommendations.
(12.00 in.) crossmember spacing. For other crossmember
NOTE: Thermo King supplies the Fuel Tank, Fuel Tank Hangers, Fuel spacing, refer to TK drawing 5937C22.
Tank Channels and Fuel Tank Straps. Due to differences in trailer
manufacturers, additional support channels may be required to 2. Torque 1/2 in. hardware to 81 - 88 N•m (60 - 65 ft/lb).
safely support the overall weight of the fuel tank components 3. Torque 3/8 in. hardware to 48 N•m (35 ft/lb).
including the full capacity of diesel fuel. Consult your trailer
manufacturer for specific details on proper fuel tank installation and 4. Torque band clamping hardware to 48 N•m (35 ft/lb).
recommendations. 5. Route fuel lines from fuel tank, through conduit and connect to unit.
Clamp every 609.6 mm (24.0 in.).
6. Thermo King recommends the fuel tank be mounted 203.2 mm
(8.00 in.) inside of the trailer frame. Otherwise, the OEM or installer is
responsible to ensure the fuel tank position meets or exceeds DOT or
Federal Highway regulations, when applicable.
7. Position fuel line 228.6 mm (9.00 in.) from center line of trailer.
38
Installing the Fuel Tank
39
Installing the Fuel Lines
5. Route fuel supply line from the unit to the fuel pump to the fuel pickup
DANGER: Leaking fuel lines could cause a fire resulting in
on the fuel tank. Install fuel line connector (provided in installation kit),
death or serious injury! All fuel line fittings must be tight and
leak free! cut end of fuel line at a 45 degree angle and insert into fuel pickup tube
until it is 25.4 mm (1.00 in.) from bottom of tank and tighten securely
DANGER: Do not route fuel lines with battery cables or (Detail IV).
electrical wires, as this could cause a fire!
6. Route fuel return line from the unit to the fuel tank return fitting.
Attach fuel line connectors and tighten securely.
1. Install the fuel line bracket to the pre-drilled hole in the frame. This
hole is located in the frame under the compressor (Detail I). 7. Remove plastic cap from the fuel vent and point the outlet to the rear of
the trailer.
2. Fuel lines should be routed in a protective housing with no kinks or
sharp bends (Detail II). NOTE: Add a sufficient amount of fuel (1/4 tank) to allow the unit to
run for 8 to 12 hours during engine break-in and pre-delivery
3. Rubber grommets must be used when routing fuel lines through holes procedures.
in metal (Detail III).
4. Secure all fuel lines with provided clamps (Detail III).
40
Installing the Fuel Lines
41
Installing the Status Light Kit (Option)
42
Installing the Status Light Kit (Option)
43
Installing the Rear Remote Controller (Option)
DANGER: Do not route electrical harness together with fuel 3. Drill an appropriate size hole in the controller box for the harness chase
lines as this could cause a fire resulting in death or serious coupling.
injury! 4. Install harness chase coupling.
NOTE: Coupling should not protrude more than 6.4 mm (0.25 in.)
CAUTION: Do not drill holes into refrigeration, electrical or
mechanical components or severe damage to the equipment inside the controller box.
will result! 5. Install cap in bottom of controller box before foaming trailer wall.
Preferred Wire Routing (Steps 1,2, 6-10) 6. Apply chalking to controller box and install securely into trailer wall.
NOTE: The preferred routing of the electrical harness chase and 7. Apply Superlube (or equivalent) to interface harness connector and
interface harness is from the bottom of the controller box. attach securely to back of controller. Route interface harness through
chase. Secure controller to controller box with screws.
1. Connect the harness chase to the bottom of controller while providing a
drip loop. 8. Route chase and interface harness from controller to host unit. Secure
with clamps.
2. Install and route a 1/2 in. CPVC drain hose from the bottom of the
controller box out of trailer floor. 9. Cut off excess harness and strip wire ends. Crimp onto existing splice
and use heat shrink covering.
10. Apply Superlube (or equivalent) and secure connect remote interface
harness connector to evaporator harness connector.
A. 69.8 mm (2.75 in.)
B. 196.8 mm (7.75 in.)
44
Installing the Rear Remote Controller (Option)
45
Installing the Rear Remote Controller (Option)
Retro-Fit Installation
NOTE: Verify mounting location and all dimensions before installing 4. Apply caulking to remote controller with interface connector harness,
the remote controller. route harness down chase and forward to unit.
DANGER: Do not route electrical harness together with fuel 5. Route harness under trailer through chase in floor or I-beam cross
lines as this could cause a fire resulting in death or serious members towards the unit.
injury!
6. From inside the trailer, measure and drill an appropriate size hole and
route the harness up into the trailer towards the unit.
CAUTION: Do not drill holes into refrigeration, electrical or
mechanical components or severe damage to the equipment 7. Secure harness to the backside of the unit with clamps.
will result!
8. Measure the length of harness required to connect to host unit
CAUTION: Rubber grommets must be used when routing evaporator harness connector, cut off excess harness and strip wire
electrical harnesses through metal holes! ends. Crimp into existing splice and use heat shrink covering.
9. Securely connect the remote interface harness to the evaporator harness
1. Cut opening in trailer wall per dimensions shown. connector.
2. Install and route a 1/2 in. CPVC drain hose and 0.88 O.D. harness A. 203 mm (8.0 in.)
chase from the bottom of the controller box out of the trailer.
B. 107.9 mm (4.25 in.)
3. Apply caulking to controller box and install securely in trailer wall.
C. 38 x 12.7 mm (1.5 x .5 in.)
NOTE: Make sure the drain hose and harness chase are connected
properly.
46
Installing the Rear Remote Controller (Option)
47
Installing the Door Switch (Option)
NOTE: These instructions are intended as reference guide only to assist with a typical door switch installation. Your installation may be different
depending on the trailer, the amount and types of doors and the customers particular requirements.
Door Switch Components • It is important that a maximum gap of 19 mm (0.75 in.) is maintained
The door switch consists of a magnet, a switch, non-magnetic mounting between the door switch and the magnet. Shims may be required and
hardware and a interface harness to connect to the host unit. must be a non-magnetic material (aluminum, wood, plastic, etc.) or the
door switch will not operate properly.
• The magnet is always mounted on the door.
• The switch (with harness) is always mounted to a stationary location. (Detail A) Ceiling Mounted
• Two short interface harnesses are available depending on your 1. Mount the magnet flush with the top edge of the door and secure with
particular kit. One allows a single door switch in a single zone to supplied hardware.
activate a unit shutdown. The other allows two door switches in the 2. Close the door and mount the switch to the door sill parallel with the
same zone to each activate a unit shutdown. magnet, being sure the “cross hairs” are aligned and that the maximum
Non-magnetic mounting hardware is included to install the switches. If gap of 19 mm (0.75 in.) is maintained.
alternate hardware is used it must also be non-magnetic or the door switch (Detail B) Floor Mounted
will not operate properly.
1. Mount the magnet flush with the bottom edge of the door and secure
Installer is to supply and fabricate the harness connecting the interface
with supplied hardware.
harness to the door switch per the table below. The harness should be 18
AWG or better, 3 wires, color coded RED, BLACK and WHITE. 2. Close the door and mount the switch to the floor parallel with the
Interface Harness Wiring Door Switch Wiring magnet, being sure the “cross hairs” are aligned and that the maximum
gap of 19 mm (0.75 in.) is maintained.
RED = (12 Vdc) POWER RED = (12 Vdc) POWER
BLACK = (CH) GROUND BLACK = (CH) GROUND
(Detail C) Outside Door Installation
WHITE = (DS) OUTPUT WHITE = (DS) OUTPUT
1. Mount the magnet flush with the top edge of the door and secure with
Mounting Locations supplied hardware.
The door switch can be mounted on the inside or outside of either swing
out or roll-up doors and can be mounted in various positions to 2. Close the door and mount the switch to the door sill parallel with the
accommodate particular applications. magnet, being sure the “cross hairs” are aligned and that the maximum
gap of 19 mm (0.75 in.) is maintained
IMPORTANT INSTALLATION NOTES:
• The door switch must be installed away from traffic (i.e. forklifts) or
protected from it.
• The door switch and magnet must be installed parallel to each other,
not perpendicular. Long cross hair aligns to long cross hair.
48
Installing the Door Switch (Option)
49
Installing the Door Switch (Option)
NOTE: The Door Switch Harness Connectors are located at the rear of the host unit.
Single Door Switch Activation / Single Zone (Detail A) Multiple Door Switch Activation / Single Zone (Detail B)
1. Attach the interface harness (1E29281) to matching door switch 4. Attach the interface harness (1E30238) to matching door switch
connector (Zone 1, 2 or 3) located at the rear of the host unit. connector (Zone 1, 2 or 3) located at the rear of the host unit.
2. Route a 3 wire harness (INSTALLER SUPPLIED) from the interface 5. Route a 3 wire harness (Installer Supplied) from the interface harness
harness to a single door switch. Connect matching wires per the table to each door switch in that zone - Maximum Two Doors. Connect
below (RED/RED, WHITE/WHITE, BLACK/BLACK) to each matching wires per the table below (RED/RED, WHITE/WHITE,
door switch using splice connectors. Crimp splice connectors securely BLACK/BLACK) to each door switch using splice connectors. Crimp
and apply heat with a heat gun. splice connectors securely and apply heat with a heat gun.
Interface Harness Wiring Door Switch Wiring Interface Harness Wiring Door Switch Wiring
RED = (12 Vdc) POWER RED = (12 Vdc) POWER RED = (12 Vdc) POWER RED = (12 Vdc) POWER
BLACK = (CH) GROUND BLACK = (CH) GROUND BLACK = (CH) GROUND BLACK = (CH) GROUND
WHITE = (DS) OUTPUT WHITE = (DS) OUTPUT WHITE = (DS) OUTPUT WHITE = (DS) OUTPUT
3. All harnesses should be installed, routed and properly secured to 6. All harnesses should be installed, routed and properly secured to
protect from damage. protect from damage.
7. Operate unit and verify door switch operation.
50
Installing the Door Switch (Option)
Interface Harness Wiring Door Switch Wiring
RED = (12 Vdc) POWER RED = (12 Vdc) POWER
BLACK = (CH) GROUND BLACK = (CH) GROUND
WHITE = (DS) OUTPUT WHITE = (DS) OUTPUT
51
CargoWatch Sensor Locations
52
CargoWatch Sensor Locations
53
Connecting the CargoWatch Sensors
CONNECTING SENSORS 6. Insert BLACK pin connector and wire into correct connection until it
locks into position (Detail I). The wire side of the connector is shown.
1. Locate the Sensor Interconnect Harness behind the evaporator access
SENSOR PLUGS
panel.
1 Black into #12
2. Unplug the connector from the harness.
2 Black into #11
3. Removes orange end from connector. 3 Black into #10
4. Remove only the plugs from the connector holes for the sensors you are 4 Black into #9
connecting. Unused holes must remain plugged. 5 Black into #8
SENSOR PLUGS 6 Black into #7
1 #1 and #12
Reinstall orange end (3) back onto connector (2), apply a light coating
2 #2 and #11 of Superlube to electrical connections and plug sensor back into mating
3 #3 and #10 connector on the Sensor Interconnect Harness (1).
4 #4 and #9
7. Connect the Sensor Interconnect Harness to the sensor using the splice
5 #5 and #8
connectors. Crimp splice connectors securely and apply heat with a
6 #6 and #7 heat gun.
5. Insert WHITE pin connector and wire into correct connection until it 8. Secure sensor with appropriate clamps.
locks into position (Detail I). The wire side of the connector is shown.
SENSOR PLUGS
1 White into #1
2 White into #2
3 White into #3
4 White into #4
5 White into #5
6 White into #6
54
Connecting the CargoWatch Sensors
55
Connecting the DAS Sensors - SB-200TG ONLY
56
Connecting the DAS Sensors - SB-200TG ONLY
57
Installing the Bulkhead (Option)
58
Installing the Bulkhead (Option)
59
Installing the Battery
CAUTION: Set all electrical controls to the OFF position before Optional Heavy Duty Battery Hold Down
connecting the battery to prevent the unit from starting! Bracket
1. Install the battery into the tray.
CAUTION: Always wear protective clothing, gloves and eye
wear when handling and installing batteries! 2. Install the battery hold down bracket and rods. Loosely install hardware
onto the rods.
CAUTION: Cover battery terminals to prevent accidental NOTE: One of the hold down rods must fit into the notch located on
shorting during battery installation! the channel under the battery. You may have to move the electrical
harness slightly to access this notch.
Standard Battery Hold Down Bracket 3. Align the tab of the battery hold down bracket over the two existing
holes in the frame support channel.
1. Install battery into the tray and secure with hold down bracket and rods.
Tighten the two battery hold down rods to 2.25 N•m (20 in -lbs.) NOTE: Units built prior to March 2010 will require the two existing
DO NOT over tighten as this may crack or distort the battery! holes in the frame support channel be drilled completely through the
channel using a 0.266 dia. (H) drill bit.
NOTE: One of the hold down rods must fit into the notch located on
4. Install the two mounting bolts and flat washers through the hold down
the channel under the battery. You may have to move the electrical
bracket and support channel. Install the flat washers and locking nuts
harness slightly to access this notch.
and torque hardware to 13.5 N•m (120 in-lbs).
2. Install positive + battery cable on the positive battery post first to
5. Tighten the two battery hold down rods to 2.25 N•m (20 in -lbs.)
minimize accidental electrical shorting.
DO NOT over tighten as this may crack or distort the battery!
3. Install negative - battery cable on negative battery post second to
6. Install positive + battery cable on the positive battery post first to
minimize accidental electrical shorting.
minimize accidental electrical shorting.
7. Install negative - battery cable on negative battery post second to
minimize accidental electrical shorting.
60
Installing the Battery
Standard Optional
Battery Hold Down Bracket Heavy Duty Battery Hold Down Bracket
61
Installing the Bottom Pan
NOTE: It is recommended that a anti-seize lubricant be applied to the threads of the stainless steel mounting hardware.
62
Installing the Bottom Pan
SB-110, SB-210 and SB-310 Units SB-200TG Units Only
63
SYSTEM CHECK LIST
All unit mounting hardware torqued to specifications. Battery secured correctly and all connections clean and tight.
No air gaps between unit and trailer wall. Doors, covers, guards and bottom pan installed securely.
Drain hoses properly routed and secured. Run Pre-Trip test (refer to Host Unit Operating Manual).
Fuel tank properly installed. Run unit under load for eight hours to properly break-in engine.
Fuel lines properly routed and fuel fittings tightened securely. Release to customer.
Bulkhead properly designed and installed.
64
Troubleshooting Guide
All Thermo King refrigeration units are pre-tested at the factory prior to shipping. If your unit has problems after installation, check the items listed below
first. If further assistance is required, consult your Thermo King dealer
Diesel engine cranks over but will not start No fuel Add fuel to tank
Kinked/pinched fuel lines Check fuel line routing
Fuel lines connected wrong at tank or unit Check connections
Air in fuel lines Bleed air from fuel lines
Diesel engine starts but lacks power Air in fuel lines Bleed air from fuel lines
Low fuel pressure Check fuel lines for kinks
Rattling noise from unit when running Loose component Secure doors
Secure grilles
Secure guards and covers
Ice buildup on evaporator coil Evaporator coil restriction Check for bulkhead blocking air return inlet
Check for pinched or kinked drain hoses
Air leakage into trailer Check installation of sill gasket
65
66
TK 52768-2-IM (Rev. 6, 02/13)
Installation Manual